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Hyosung · Shim-adjusted overhead-cam four-stroke, wet sump, gearbox shares engine oil, chain drive

GV 250

Library entry covers 2000-2017

21 factory 34 guideline

Published source

Hyosung GV250 Owner's Manual, Periodic Maintenance p.19 (factory PDF, copy on archive.org)

Factory owner's handbook. Covers GV250 (carburetor) owner's manual, undated early edition.

Open the source

55 items for a 2002 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, shim adjusted (incl. desmo)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Two or more carburetors
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Drum (or band / belt rim)
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2002 Hyosung GV 250

On the road: every 300 km

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 500 km

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

On the road: every 1,000 km

2 items

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Factory

Manual: Drive chain. Factory: Clean and lubricate every 1,000 km.

Every 1,600 km or 6 months

1 item

Adjust rear drum brake and rod / cable linkage

Brakes

Guideline

Every 3,000 km

1 item

Clean / inspect air filter

Fuel and air

Factory

Manual: Air cleaner element. Factory: Clean every 3,000 km (printed across columns).

Every 4,000 km or 2 years

1 item

Replace brake fluid

Brakes

Factory

Manual: Brake fluid. Factory: Inspect every 4,000 km; replace every 2 years.

Every 4,000 km or 4 years

2 items

Replace fuel lines

Fuel and air

Factory

Manual: Fuel hose. Factory: Inspect every 4,000 km; replace every 4 years.
Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Brake hose. Factory: Inspect every 4,000 km; replace every 4 years.

Every 4,000 km

14 items

Change engine oil

Engine

Factory

Manual: Engine oil. Factory: Replace at 1,000 km then every 4,000 km.
Chassis nuts and bolts

Engine

Factory

Factory: Tighten.
Check and adjust valve clearances

Engine

Factory

Manual: Valve clearance adjust. Factory: Inspect at 1,000 km then every 4,000 km. Cols: First 1,000 / Every 4,000 / Every 8,000 km.
Exhaust pipe bolts and muffler mounting bolts

Engine

Factory

Factory: Tighten at 1,000 km then every 4,000 km.
Idle speed

Engine

Factory

Factory: Inspect.
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plug. Factory: Clean/inspect at 1,000 km then every 4,000 km.
Replace oil filter

Engine

Factory

Manual: Engine oil filter. Factory: Replace at 1,000 km then every 4,000 km.
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Throttle cable. Factory: Inspect.
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch. Factory: Inspect.
Check steering head bearing adjustment

Front end

Factory

Manual: Steering. Factory: Inspect.
Inspect fork seals, stanchions and fork boots

Front end

Factory

Manual: Front forks. Factory: Inspect; not at 1,000 km.
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Rear suspension. Factory: Inspect; not at 1,000 km.
Check brake pads and discs

Brakes

Factory

Manual: Brake. Factory: Inspect.
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Tire. Factory: Inspect.

Every 5,000 km or 12 months

6 items

Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 6,500 km or 12 months

1 item

Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 8,000 km

1 item

Replace spark plugs

Engine

Factory

Manual: Spark plug. Factory: Replace in Every 8,000 km column.

Every 9,500 km or 12 months

6 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Synchronize carburetors

Fuel and air

Guideline
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 12,000 km

1 item

Replace air filter element

Fuel and air

Factory

Manual: Air cleaner element. Factory: Replace every 12,000 km.

Every 16,000 km or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 19,500 km or 2 years

2 items

Clean and grease rear suspension linkage

Rear suspension and frame

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 24,000 km or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 24,000 km or 4 years

1 item

Check valve clearances (shim adjusted)

Engine

Guideline

Every 24,000 km

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 29,000 km

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 32,000 km or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

2 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline

Every 4 years

1 item

Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.